Stabilization of fabric surfaces

ABSTRACT

A textile fabric having improved properties, variously including surface stability, abrasion resistance, resistance to edge fraying, moisture control, and resistance to fluid penetration is created by introducing a polymeric solution or a plurality of low-melting particles suspended in a liquid into the textile fabric while leaving a plurality of surface fibers exposed and maintaining a textile feel on the surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 16/031,603 filed Jul. 10, 2018, which claimspriority to U.S. Provisional Patent Application No. 62/530,621 filedJul. 10, 2017. The entire contents of which are incorporated herein byreference.

TECHNICAL FIELD

Embodiments of the subject matter disclosed herein relate to textilesheets and floor coverings.

BACKGROUND

Textile flooring and other textile surface-coverings, for example,wallcoverings and upholstery, at a minimum require surface stability andabrasion resistance. The required surface stability and abrasionresistance are needed without excessive hardening of the surface andwith the preservation of at least some “textile feel” or textile look.Textile flooring and textile surface-coverings often have texturedthree-dimensional surfaces, including highly textured or deeply embossedsurfaces, and the structure of the textured three-dimensional surfacesneeds to be maintained under severe end use conditions associated, forexample, with flooring and upholstery.

While three-dimensionally formed fabrics and flat fabrics withthree-dimensional textured surfaces may be abrasion-resistant, thefibers at the cut edges of these fabrics are typically not anchoredsufficiently close to the exposed tips at the cut edges. Theseinsufficiently anchored fibers tend to fray or “fuzz”. When used as asurface covering such as a floorcovering or wall covering, the fabricsare grouped together, forming seams where adjacent cut edges meet. Thegrouped fabrics containing the insufficiently anchored fibers candevelop visible lines of deterioration over time along the seams, evenunder conditions of normal use.

Flooring and related surface-covering applications utilizingthree-dimensionally formed fibrous surfaces may also require materialsand fabrics that provide a combination of breathability and simultaneousresistance to spilled fluid penetration. Breathability is usuallydefined as the transmission of a minimum amount of water vapor per 24hrs, and resistance to spilled fluid penetration is usually defined bythe British Spill Test. According to the British Spill Test, waterdropped onto a sheet of material from a height of 1 meter is required tofail to penetrate and breach the backside of that sheet of material fora period of at least 24 hrs.

Attempts at preventing liquids spilled on the surface of a fabric orfloorcovering from breaching the backside have in the past used films ormembranes attached to the bottom of the sheet. These arrangementshowever allow the spills to penetrate the top surface of the sheet ofmaterial, and only stop liquid penetration at the bottom. Therefore, theliquid penetrates into the lower layers of the sheet of material. Thispenetration into the lower layers can promote the formation and growthof bacteria or fungi within the lower layers.

Alternate attempts at using a film or membrane to resist the penetrationof spills are described, for example, in U.S. Pat. No. 5,965,232 toVinod, U.S. Pat. No. 7,425,359 to Zafiroglu and U.S. Pat. No. 7,431,975to Zafiroglu. These alternate attempts place the membrane between arelatively thin textile fabric surface and a cushioning backing to forma preferably breathable floorcovering that allows water vapors to escapebut that resists the penetration of liquids from spills. The membrane isattached to the structure with adhesive layers. These adhesive layersmake obtaining good delamination resistance without limiting or fullyblocking breathability difficult. U.S. Patent Application PublicationNo. 2013/0280486 to Zafiroglu discloses a liquid-blocking compositehaving a fibrous surface layer and a membrane placed directly under thesurface layer. The surface layer may optionally have a texture deeperthan the original thickness of the fibrous surface layer. The resultingliquid-blocking composite has low breathability and low water vaportransmission capability resulting, at least partially, from thenecessity to use relatively high weights of adhesive.

Therefore, a need exists for fabrics, including highly-textured fabrics,that maintain high resistance to abrasion and surface deformation withuse, and preferably also block the flow of liquids into the inner layersof the fabric while maintaining a textile appearance and textiletexture. The fabrics would also preferably “breathe” to allow thetransmission of water vapor. The highly-textured fabrics would have atleast a portion of the surface fibers or surface loops exposed and freeof adhesive or resin. Therefore, the surface would not lose its textileand fibrous feel by being hardened and solidified. In addition, a needexists for a reliable and flexible method to make these highly-texturedfabrics with special face aesthetics, or special properties such asmicrobial resistance, or soiling resistance.

SUMMARY

Exemplary embodiments are directed to methods for making improvedtextile fabrics and composites containing fabrics by using a pluralityof low-melting polymeric particles deposited onto the surface. Thedeposited particles are guided into the interstices or gaps among thefilaments, fibers or yarns exposed on the top surface of the textilefabric and also into the depressed areas of the textured top surface ofthe textile fabric. The particles are then activated with heat. Thetextile fabrics retain a textile feel and may be free-standing orattached to a backing. Suitable backings include, but are not limitedto, bulky cushioning backings.

In one embodiment, the deposited low-melting polymeric particles aredirected to the more desired areas of the surface of the fabric. In oneembodiment, the plurality of low-melting polymeric particles is in theform of a fine powder. In one embodiment, the particles in the pluralityof low melting particles include coarser particles. Suitable methods forforming or obtaining these coarser particles include freeze-grindingrecycled polymeric textiles.

In one embodiment, the fabrics are flat but have a textured surface. Inone embodiment, the textured surface is formed by yarns that loop intoand out of the surface, creating elevated areas of yarn and depressedareas of yarn. In one embodiment, the surface is textured by embossingthe surface with a three-dimensional pattern. This three-dimensionalpattern creates raised areas of fabric and lowered areas of fabricspaced across the textile fabric at intervals larger than spacings amongthe elevated areas or yarns and depressed areas of yarns and extendinginto the textile fabric at depths greater than the depths of thedepressed areas of yarns. In one embodiment, the raised and loweredareas of fabric extend to a depth that is greater than the originalthickness of the textile fabric.

Both the type of particle and the technique used for particle depositionare selected to ensure that the deposited particles at the elevatedareas of yarns or the raised areas of textile fabric stay primarilywithin a short depth under the top surface of the textile fabric. In oneembodiment, the plurality of particles is deposited onto the fabric bysifting, with or without the help of vacuum, blowing of air, orvibration during or after deposition. Particle size is chosen toapproach, match, or exceed the dimensions of the interstices or gaps ofthe fabric surface to avoid excessive propagation below the top surface.Therefore, the particles, as deposited, remain on the top surface orwithin the upper strata of the fabric.

In one embodiment, the deposited particles are activated with heat.Suitable heat sources include, but are not limited to, radiant heat, hotair, and a heated contact surface applied with low pressure. In oneembodiment, activation of the deposited particles is achieved by raisingthe temperature of the entire fabric to a level sufficient to melt theparticles. In one embodiment, the particles are activated as the fabricis embossed with the three-dimensional pattern using a heated toolequipped with surface projections. In one embodiment, the particles areactivated while the fabric is laminated to a barrier layer or to abacking layer. Lamination to the barrier layer or backing layer can beachieved with a relatively flat heated tool resulting in a compositewith the general pattern of the texture originally formed in the fabricpreserved. Alternatively, lamination to the backing layer is achievedwith a three-dimensional heated tool forming deeper and coarser facetextures that exceed the original thickness of the fabric. Embossingwith a depth exceeding the original thickness of the fabric may utilizea soft and resilient back-up tool such as silicon rubber. Embossingagainst a conformable cushioning backing removes the need for a softback-up tool as the fabric forms into the backing,

In one embodiment, the depth to which the resulting melted particleresin proceeds into the interstices or gaps among the surface fibers iscontrolled by adjusting the melt index of the deposited particles, e.g.,the powdered resin. In one embodiment, the degree of propagation ofmelted particle resin into the textile fabric is further controlledthrough the selective application of hot air or cold air to the topsurface of the textile fabric. In one embodiment, vacuum is appliedunder the fabric, i.e., to the bottom surface opposite the top surface,or under the composite containing the textile fabric as a face layer tocontrol the degree of propagation of the melted particle resin into thefabric.

Exemplary embodiments utilize limited amounts or levels of particles toprevent the addition of significant weight to the fabric while stillimproving surface durability at the elevated areas of yarns or raisedareas of fabric, fuzzing resistance at the cut edges, and overall fluidpenetration resistance. Limited levels of deposited particles achievethese improvements without eliminating the fibrous feel of the topsurface of the textile fabric or composite into which the textile fabricis incorporated. In one embodiment, the deposited particles are directedpreferentially toward the lowered areas of a deeply embossed textilefabric to overcome the locally reduced resistance to fluid penetrationby the embossing action.

In one embodiment, the textile fabric or floorcovering is treated withrepellent solutions before or after the application of low-melt powder.In one embodiment, elevated areas of yarns are relieved of the extradeposited powder, and the extra powder is moved into the depressed areasof yarns, by brushing, preferably as vacuum is applied underneath.

In one embodiment, the exposed “high-profile” or “elevated” areas of thetop surface of the fabric are stabilized by using a limited weight ofparticles or powder containing relatively coarser particles so that onlyparts of the elevated areas of yarns are covered by the resulting meltedparticle resin and parts are exposed to preserve a textile feel.

In one embodiment, the particles, are sifted upon the textile fabric. Inanother embodiment, the particles are incorporated into a liquid, e.g.,water, and the suspension is applied to the top surface of the fabric.In one embodiment, an additional wet brushing with liquid free ofparticles is applied to the top surface of the textile fabric in theelevated areas of yarns or raised areas of textile fabric to driveparticles into the fiber interstices before the textile fabric is driedand the particles are melted. The liquid in the suspension can beevaporated following application, for example, by heating in an oven,using radiant heat, applying a vacuum or blowing hot air.

In one embodiment, the depth of penetration of the particles isregulated by selecting the size of the particles in comparison to thesize and density of the fibers or yarns on the surface of the fabric. Inone embodiment, vacuum is applied to a bottom surface of the fabricopposite the top surface as the fabric is vibrated during or after thedeposition of the particles. Vacuum and vibration are also used tocontrol the depth of penetration of the particles. In one embodiment,the applied particles have the same size. Alternatively, particleshaving different configurations, compositions or densities are appliedsimultaneously or in consecutive stages. In one embodiment, a mixture ofparticle sizes is used to allow some of the finer particles to penetratethe surface fibers or yarns while some of the coarser particles stayover the top surface. This mixture of particles further improves theabrasion resistance of the top surface. In one embodiment, the coarserparticles settle at the depressed areas. After heat is applied to meltthe coarser particles, the resulting melted particle resin remainslocally above the fibers at a lower profile than the elevated areas ofyarns or raised areas of fabric without causing the loss of textile andfibrous surface aesthetics.

Suitable particles include, but are not limited to, fine polymericpowders commercially used in processes such as the bonding of non-wovensand coarser powders produced by grinding low melt polymers includingpolymers contained in recycled fabrics or floorcoverings. These powderscontain particles having a range of particle sizes suitable for use withthe fabrics. Suitable particles also include particles derived andextracted from recycled textiles containing low-melting fibers or filmsgrounded into appropriately fine particle or powder size.

In one embodiment, non-melting fine elements are mixed with theplurality of particles either before or after the application of theparticles in order to obtain special effects. These fine elements anddesired effects include colored particles for aesthetic purposes, hardparticles to increase resistance to abrasion, and particles reacting tomoisture or heat to produce special visual or functional effects,including but not limited to breathability, moisture absorbency andmoisture repellency at the surface.

In one embodiment, the original fabric contains a fluid barrier layerthat upon deep embossing stays intact at the elevated areas of yarns andraised areas of textile fabric but is perforated and compromised at thehighly compressed and indented lowered areas of textile fabric.Preferential deposition of powder into the lowered areas of textilefabric partially or totally seals the compromised lowered areas withoutseriously affecting the fibrous feel of the raised areas.

In one embodiment, particles having at least one of larger sizes andlower melt indexes that tend to stay on the top surface are combinedwith, preceded by, or followed by finer or higher melt-index particlesthat tend to penetrate in order to create special surface effects. Inone embodiment, the particles include a mixture of ground recycledhigh-melt and low-melt fabrics, textiles or polymers, mixed with atleast one of low melt powders, high melt powders, other non-meltingparticulates and special-effect particulates. These additional powdersare added to affect one or more of color, abrasion resistance, surfaceabsorbency, repellency and bacterial resistance among other surfaceproperties.

Exemplary embodiments are directed to a textile fabric having aplurality of yarns. The yarns have a yarn melting point. The yarnsinclude upper parts adjacent a top surface of the textile fabric. Aplurality of filaments forms the yarns with a plurality of gaps disposedamong the filaments. The textile fabric includes a plurality of elevatedareas of yarns and depressed areas of yarns formed by the plurality ofyarns looping in and out of the fabric. Melted particle resin resultingfrom a plurality of particles being dispersed in gaps located in theelevated areas of yarns and melted is contained in the textile fabric.The plurality of particles has a particle melting point lower than theyarn melting point. The elevated areas of yarns include sections offilaments free of melted particle resin. In one embodiment, the meltedparticle resin is concentrated in the upper parts of the yarns in theelevated areas of yarns, under the surface itself.

In one embodiment, the textile fabric also includes a barrier layerattached to a bottom surface opposite the top surface and amacro-pattern embossed into the textile fabric. The macro-patternincludes raised areas of the textile fabric and lowered areas of thetextile fabric. Adjacent raised areas and adjacent lowered areas arespaced at intervals wider than the spacing between adjacent elevatedareas of yarns and depressed areas of yarns. In addition, the loweredareas of the textile fabric have a lowered area depth that is deeperthan a depressed area depth formed originally by the yarns. In oneembodiment, the particles are present within the lowered areas of thetextile fabric at a higher concentration than within the raised areas ofthe textile fabric, and the melted particle resin in the lowered areasof the textile fabric is located below a level of the raised areas.

In one embodiment, the textile fabric is a nonwoven layer formed withfilaments or staple fibers. In one embodiment, the textile fabricincludes a cushion layer attached to the barrier layer. In oneembodiment, the plurality of gaps has a plurality of gap widths. Theseplurality of gap widths include widths less than about 100 microns. Inone embodiment, the particles in the plurality of particles have aparticle diameter of from about 400 microns to about 700 microns. In oneembodiment, the particles in the plurality of particles are dispersed ata weight of up to about 2.6 oz/yd². The plurality of particles includesat least one of low-melting particles and non-melting particlesconfigured to impart at least one of desired properties or visualeffects to a top surface of the textile fabric.

Exemplary embodiments are also directed to a method for improvingsurface and cut-edge stability of a textile fabric having a texturedsurface without losing the fibrous feel of the surface. A textile fabrichaving a plurality of yarns and a plurality of gaps disposed within theyarns is selected. The yarns loop into and out of the textile fabricforming a pattern of elevated areas of yarns and depressed areas ofyarns. The yarns have a yarn melting point. A plurality of particles isdispersed on the textile fabric. The particles have a particle meltingpoint lower than the yarn melting point. At least a portion of theplurality of particles are caused to enter the gaps within the elevatedareas of yarns on a top surface of the fabric. The plurality ofparticles is melted in situ to create melted particle resin, and atleast a portion of the filaments in the yarns within the elevated areasare left free of melted particle resin.

In one embodiment, a first plurality of particles on the textile fabricis dispersed at a first time, and a second plurality of particles isdispersed on the textile fabric at a second time. The first plurality ofparticles is separate from the second plurality of particles, and thefirst time and second time are discrete periods of time. In oneembodiment, the plurality of particles is dispersed across the textilefabric in accordance with a predetermined pattern by sifting theplurality of particles onto a top surface of the textile fabric. Inaddition, at least one of applying vacuum to a bottom surface of thetextile fabric opposite the top surface, vibrating the textile fabric,blowing air onto the top surface, sweeping the top surface, brushing thetop surface, and cold pressing the textile fabric is performed tominimize particle exposure at the elevated areas of yarns and to promoteparticle concentration at the depressed areas of yarns.

In one embodiment, dispersing the plurality of particles includesincorporating the plurality of particles into a liquid suspension,applying the liquid suspension to the top surface of the textile fabricand evaporating liquid from the liquid suspension after applying theliquid suspension to the top surface. In one embodiment, the textilefabric is embossed prior to dispersing the plurality of particles with amacro pattern containing raised areas of the textile fabric and loweredareas of the textile fabric. The plurality of particles is directed toconcentrate at the lowered areas using at least one of vacuum, brushing,sweeping, vibration and cold pressing. In one embodiment, a barrierlayer is attached to a bottom face of the fabric opposite the top face.In one embodiment, a cushioning backing layer is attached to the barrierlayer.

Exemplary embodiments are also directed to a method for creating aliquid-blocking three-dimensionally textured textile fabric with ahighly durable and fibrous textile surface and non-fraying cut edges. Atextile fabric having filaments on a top surface and a liquid blockingbarrier attached to a bottom surface opposite the top surface isembossed using an embossing pattern that forms raised areas of fabricand lowered areas of fabric on the top surface. A plurality of particlesis dispersed on the top surface, and the particles deposited on theraised areas to are directed enter the gaps between the filaments. Theparticles disposed on the top surface move towards and into the loweredareas, and heat is applied to melt the particles in the gaps and theparticles that moved into the lowered areas. A sufficient amount ofparticles are moved into the lowered areas that melted particle resinresulting from the particles in the lowered areas being melted seals thelowered areas and eliminates failure of the liquid blocking barrier dueto the embossing action.

In one embodiment, at least one of vacuum, brushing, sweeping,vibration, blown air and cold pressing is used to move the particlesinto the lowered areas. In one embodiment, a backing layer is attachedto the barrier layer. In one embodiment, at least one of low-meltingparticles and non-melting particles selected to impart at least one ofdesired properties or visual effects to the top surface are dispersed onthe top surface.

In one embodiment, polymers are dissolved in suitable chemicals andapplied to the surface of the various fabrics in amounts and viscositiesconfining the penetration of the dissolved polymer near the surface.Additional solvent is then applied to the surface to force part of orall the polymeric solution under the surface before applying heat,forced air, vacuum, or combinations thereof to evaporate the solvent andleave most of the dissolved polymer in a layer under the surface,maintaining the textile feel of the surface.

In one embodiment, the liquid suspension or polymeric solution isapplied by immersion, including partial immersion of the fabric andcomplete immersion of the fabric to reach the entire fabric. In oneembodiment, immersion of the fabric is followed by one or more ofsqueezing or applying pressure to the fabric, applying vacuum to thefabric or directing forced air on the fabric to extract any extra liquidfrom the fabric. In one embodiment, additional liquid or solvent isapplied to the surface of the fabric before applying heat to the fabricto drive the particles or the polymer solution under the surface,preserving the fibrous look and feel of the surface.

The use of a polymeric solution improves the ability to reach theinterstices between fibers, fiber bundles or the spaces within andaround yarns and yarn bundles. In addition, the viscosity of thepolymeric solution can be adjusted by adjusting the ratio of polymer tosolvent. Volatile solvents are selected to ensure evaporation withoutresidue to avoid secondary problems such as soiling.

Exemplary embodiments are directed to a method for stabilizing a textilefabric that suspends a plurality of polymeric particles in a liquid tocreate a liquid suspension of polymeric particles and applies the liquidsuspension of polymeric particles to the textile fabric. In oneembodiment, a plurality of polyester, polyethylene, polypropylenepolyurethane, polyvinyl acetate, polyvinyl alcohol, polyamide or acrylicparticles are suspended in the liquid. In one embodiment, at least aportion of the polymeric particles have a chemical composition that iscompatible with fibers in the textile fabric to form chemical bonds withthe fibers. In one embodiment, at least a portion of the polymericparticles is ground recycled textile products containing powderized lowmelt content. Suitable liquids include water and water containingsurfactants.

In one embodiment, the liquid suspension is applied by immersing thetextile fabric in the liquid suspension. In one embodiment, the liquidsuspension is applied uniformly to a top surface of the textile fabric.In one embodiment, an initial volume of the liquid suspension is appliedto the top surface of the textile fabric. The initial volume issufficient to penetrate from the top surface into the textile fabricwith a penetration depth that is less than a thickness of the textilefabric.

An additional volume of the liquid is applied to a top surface of thetextile fabric. The additional volume is sufficient to carry at least aportion of the plurality of polymeric particles into the textile fabricand away from the top surface. In one embodiment, the additional volumeof the liquid is applied to the top surface by wet brushing the liquidonto the top surface, wet rolling the liquid onto the top surface,spraying the liquid onto the top surface, or combinations thereof. Inone embodiment, additives having a melting point that is higher than thetemperature applied to the textile fabric are incorporated into at leastone of the liquid suspension of particles and the additional volume ofliquid. The additives affect at least one of a color of the textilefabric, an abrasiveness of the textile fabric, an absorptiveness of thetextile fabric and antimicrobial properties of the textile fabric. Inone embodiment, a repellent is added into at least one of the liquidsuspension of particles and the additional volume of liquid.

Heat is applied to the textile fabric. The applied heat is sufficient toevaporate the liquid applied to the textile fabric and to melt theplurality of polymer particles in situ. In one embodiment, a textilefabric containing a plurality of looping yarns is selected. Theplurality of looping yarns includes an upper portion adjacent the topsurface. In one embodiment, the textile fabric is embossed with a coarsepattern containing elevated areas and depressed areas. The liquidsuspension is applied only to the elevated areas of the textile fabricembossed with the coarse pattern. In one embodiment, the textile fabriccontaining the melted polymeric particles is needled with smooth fineneedles to facilitate water vapor penetration through the textilefabric.

Exemplary embodiments are also directed to a method for stabilizing atextile fabric that dissolves a polymer in a solvent to create apolymeric solution and applies the polymeric solution to the textilefabric. In one embodiment, polyesters, polyurethanes, polystyrenes,acrylics or polyamides are dissolved in the solvent. In one embodiment,the polymers are dissolved in a volatile organic solvent. In oneembodiment, the dissolved polymer has a chemical composition that iscompatible with fibers in the textile fabric to form chemical bonds withthe fibers. In one embodiment, at least a portion of dissolved polymeris ground recycled textile products.

In one embodiment, an initial volume of the polymeric solution isapplied to the top surface of the textile fabric. The initial volume issufficient to penetrate from the top surface into the textile fabric apenetration depth that is less than a thickness of the textile fabric.In one embodiment, the polymeric solution is applied in a plurality ofdiscrete applications. In one embodiment, a viscosity of the polymericsolution is varied among the plurality of discrete applications byvarying a ratio of polymer to solvent in the polymeric solution. In oneembodiment, the textile fabric blocks water and passes water vapors.

An additional volume of the solvent is applied to a top surface of thetextile fabric. The additional volume is sufficient to carry at least aportion of the dissolved polymer into the textile fabric and away fromthe top surface. In one embodiment, additives having a melting pointthat is greater than a temperature of the heat applied to the textilefabric are incorporated into at least one of the polymeric solution andthe additional volume of solvent. The additives affect at least one of acolor of the textile fabric, an abrasiveness of the textile fabric, anabsorptiveness of the textile fabric and antimicrobial properties of thetextile fabric. In one embodiment, a repellent is incorporated into atleast one of the polymeric solution and the additional volume ofsolvent.

At least one or more of forced air, vacuum and heat is applied to thetextile fabric to evaporate the solvent applied to the textile fabricand to set the polymer in situ. In one embodiment, a nonwoven textilefabric formed with filaments or staple fibers or a textile fabriccontaining a plurality of looping yarns that form the top surface isselected. In one embodiment, a textile fabric containing a plurality oflooping yarns is selected. The plurality of looping yarns includes anupper portion adjacent the top surface. In one embodiment, the textilefabric is a stitchbonded fabric containing loops of yarn that form thetop surface. In one embodiment, the textile fabric is embossed with acoarse pattern containing elevated areas and depressed areas. Thepolymeric solution is applied only to the elevated areas of the textilefabric embossed with the coarse pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate a plurality of embodiments and,together with the following descriptions, explain these embodiments.

FIG. 1 is a schematic representation of a top view of a textile fabricwith a plurality of particles dispersed over the top surface.

FIG. 2 is a schematic representation of an embodiment of a portion of ayarn illustrating the filaments forming the yarn, the gaps among thefilaments, and the particles deposited on the yarns.

FIG. 3 is a schematic cross-sectional side view of the fabric of FIG. 1;

FIG. 4 is a schematic representation of a side view of an embodiment ofa textile fabric containing an arrangement of a plurality of particles;

FIG. 5 is the schematic representation of a cross-section of anembodiment of a textile fabric placed over a barrier layer, embossedwith a macro pattern and containing an arrangement of a plurality ofparticles;

FIG. 6 is a schematic representation of a side view of an embodiment ofa textile fabric integrated into a composite and containing anarrangement of a plurality of particles;

FIG. 7 is the schematic representation of a side view of an embodimentof a textile fabric integrated into a composite, embossed with a macropattern and containing an arrangement of a plurality of particles;

FIG. 8 is a flow chart illustrating an embodiment of a method for makinga textile fabric having an increase in surface and cut edge durability;

FIG. 9 is a flow chart illustrating another embodiment of a method formaking a textile fabric having an increase in surface and cut edgedurability; and

FIG. 10 is a schematic representation of a textile fabric with polymeror polymeric particles introduced as a solution or suspension.

DETAILED DESCRIPTION

The following description of the embodiments refers to the accompanyingfigures. The same reference numbers in different figures identify thesame or similar elements. Reference throughout the whole specificationto “one embodiment” or “an embodiment” means that a particular feature,structure or characteristic described in connection with an embodimentis included in at least one embodiment of the subject matter disclosed.Thus, the appearance of the phrases “in one embodiment” or “in anembodiment” in various places throughout the specification is notnecessarily referring to the same embodiment. Further, particularfeatures, structures or characteristics may be combined in any suitablemanner in one or more embodiments.

Exemplary embodiments are directed to incorporating low-melting adhesiveparticles or powders into the surface of a textile fabric. In oneembodiment, the particles are deposited onto the top surface of thetextile fabric by sifting. In another embodiment, the particles areapplied to the top surface of the textile fabric or floor covering as asuspension in a fluid. Suitable fluids include, but at not limited to,water and water containing surfactants mixed in low percentage levels.In all embodiments, the textile fabric or floor covering has athree-dimensional surface. The three-dimensional surface of the fabricincludes elevated areas of yarns and depressed areas of yarns. In oneembodiment, the fabric is attached to a backing. In one embodiment, theparticles descend into the interstices between and among the surfacefibers. In one embodiment, the particles descend into the gaps betweenyarns that form the surface of the fabric. In one embodiment theparticles also descend into the depressions or spaces that may be formedas the yarns are inter-looped along a generally flat surface.

The deposited particles are melted by raising the temperature of thesurface of the fabric or of the entire fabric. In one embodiment, afabric formed with looping yarns entering and exiting the surface isdeeply embossed with patterns coarser than the patterns formed by theyarns. In one embodiment the depth of the embossed patterns exceeds thepre-embossed thickness of the fabric. The embossed patterns includeraised areas of fabric and lowered areas of fabric. The particles,depending upon their size and shape may proceed by gravity predominantlyinto the lowered areas of fabric compared to the particles in the raisedareas of fabric. As the deposited particles melt to form melted particleresin, the melted particle resin flows to fill-in the gaps andinterstices and increase resistance to fluid penetration in the loweredareas, which may have been previously thinned-out or perforated duringembossing, lowering resistance to fluid penetration.

Depending upon the structure of the top surface of the fabric, thenature of the surface fibers or yarns, the amount of depositedparticles, the melt characteristics of the particles, and the structureof the deposited particles, different advantages and improvements indifferent embodiments are achieved in the textile fabric. Theseadvantages and improvements include, but are not limited to, simplestabilization of the elevated areas of yarns and raised areas of fabricversus wear and abrasion, achieving a breathable fluid barrier withminimum hardening of the textile fabric surface, and blocking of fluidpenetration through the textile fabric without excessive hardening andwithout eliminating the fibrous feel of the top surface.

Referring initially to FIG. 1 , exemplary embodiments are directed to atextile fabric 100 containing a plurality of yarns 102. As illustrated,the yarns are arranged as a knit textile fabric. However, the yarns canalso form other types of textile fabrics including, for example, wovenfabrics, stitchbonded textile fabrics and tufted textile fabrics. Ingeneral, the yarns have a yarn melting point. Each yarn is constructedfrom and contains a plurality of distinct filaments or individual fibers104.

The textile fabric includes a plurality of gaps disposed within andamong the yarns. These gaps in the plurality of gaps include spacings106 between yarns in the plurality of yarns. The size and shape of theindividual spacings varies.

These gaps also include openings 108 between individual filaments withineach yarn. The size and shape of the individual openings vary betweendifferent pairs of filaments and along the length of filaments as thefilaments are twisted and entangled. In general, each gap has a gapwidth. Therefore, the plurality of gaps represents a plurality of gapwidths. Each opening within the yarns has an opening gap width, and eachspacing between yarns has a spacing gap width, which includes largerspacing gap widths and smaller spacing gap widths. The size of the gapwidth can vary along the length of the gap. In one embodiment, anindividual gap width is the largest measured distance across the gap. Asused herein, the gap width refers to a size or dimension of a largestobject or particle that can pass through the gap. Suitable dimensionsinclude the diameter of a sphere or the diagonal of a cube. The gapwidths associated with the openings between filaments are smaller thanthe gap widths associated with the spacings between yarns. In oneembodiment, the plurality of gap widths includes widths less than about500 microns. In one embodiment, the plurality of gap widths includeswidths of from about 400 microns to about 500 microns. In oneembodiment, the plurality of gap widths includes widths less than about100 microns.

The textile fabric includes a plurality of particles 105 dispersedacross the textile fabric within the yarns. In one embodiment, theparticles in the plurality of particles include particles have the samesize and shape. In another embodiment, the particles in the plurality ofparticles include particles that vary in at least one of size and shape.As illustrated, the particles may include spherical particles. Thesespherical particles can include small particles that are smaller thanthe gap width of all of the spacings in the textile fabric, mediumparticles that are smaller than the gap width of some of the openingsbut larger than the gap width of other openings, and large particlesthat are larger than the gap width of all openings. The particles willpass into the gaps having a gap width larger than the particles. Thelarge particles will remain on the top surface of the textile fabric. Inone embodiment, a portion of the small and medium particles remain onthe top surface of the textile fabric and do not pass into the openings.In addition to spherical particles, suitable particles include particleshaving other shapes including, for example, cubic particles andnon-uniformly shaped particles.

Referring to FIG. 2 , the size and shape of the particles are alsoselected based on the gap widths of the openings between filaments inthe individual yarns. In one embodiment, the plurality of particlesincludes a first size of particles 130 that are small enough to passthrough or to penetrate the openings between filaments. In oneembodiment, the plurality of particles includes a second size ofparticles 132 larger than the first size of particles that may penetratethe spacings between yarns but is too large to pass through the openingsbetween filaments. In one embodiment, the textile fabric includes boththe first size and the second size of particles.

The particles within the plurality of particles are dispersed in atleast one of the openings between filaments and the spacings betweenyarns. In one embodiment, the plurality of particles includes particleshaving a size smaller than at least one gap width in the plurality ofgap widths. In one embodiment, the particles in the plurality ofparticles have a nominal particle size of about 82 microns. In oneembodiment, the particles in the plurality of particles have a particlesize of about 400 microns to about 700 microns.

Suitable materials for the particles include, but are not limited to,plastics and polymers. In one embodiment, the particles include at leastone of polyester particles and polyethylene particles. In oneembodiment, the particles are formed from a material or materials havinga particle melting point temperature lower than the melting point of thefibers within the yarns. Therefore, the particles can be subjected toheat and melted without melting the yarns.

Returning to FIG. 1 , the arrangement, distribution and density ofparticles is shown for illustrative purposes. The particles in theplurality of particles are introduced onto a top surface of the textilefabric in accordance with a predetermined density and distribution ofparticles. Therefore, the textile fabric can include areas ofoverlapping or stacked particles and areas containing few if anyparticles. In one embodiment at least one of a pre-determineddistribution of the plurality of particles across the textile fabric anda depth of penetration of particles in the plurality of particles intofrom the top surface through the gaps and into the fabric areestablished. The textile fabric has upper strata, i.e., the portion ofthe textile fabric adjacent the top surface, and in one embodiment, adesired depth of penetration is established such that a majority of theplurality of particles are located within the upper strata. Suitablemethods for establishing the desired distribution of particles include,but are not limited to, sifting the plurality of particles onto the topsurface and applying the particles in the liquid suspension. In oneembodiment, the particles in the plurality of particles are dispersedwithin the yarns at a weight of up to about 2.6 oz/yd².

Referring now to FIG. 3 , the yarns in the plurality of yarns form atextured surface pattern that creates elevated areas of yarns 134 anddepressed areas of yarns 136. A given yarn following the texturedsurface pattern can transition from an elevated area of yarn to adepressed area of yarn across the surface of the textile fabric. In oneembodiment, the desired pattern of distribution of particles is variedin accordance with the location of the elevated areas of yarns anddepressed areas of yarns. In one embodiment, the particles in theplurality of particles have a particle size greater than a size of thegaps among the plurality of surface fibers in the elevated areas. In oneembodiment, the particles in the plurality of particles include largerparticles and smaller particles. Most of the smaller particles pass intothe gaps among the surface fibers. The remainder of the particles,including the larger particles, fall into or are guided into thedepressed areas of yarns using, for example, vacuum, blown air,vibration, surface brushing, or a combination of two or more of theseguiding methods.

The particles in the plurality of particles are introduced or applied tothe top surface 140 of the textile fabric, for example, using sifting orapplication in a liquid suspension. In one embodiment, both the desiredpattern of particles and the desired depth of penetration can beadjusted using vacuum that is applied to a bottom surface 142 of thetextile fabric opposite the top surface 140. In one embodiment, vacuumis applied to the bottom surface simultaneously with introduction of theplurality of particles onto the top surface. Other techniques ofdistributing particles across and within the textile fabric can also beused either alone or in combination with the application of vacuum. Inone embodiment, the fabric is vibrated to control the depth ofpenetration of the plurality of particles.

In one embodiment, the textile fabric also includes a water-repellentcoating. In one embodiment, the water-repellent coating is applied andcured to the textile fabric before the plurality of particles isintroduced onto the top surface. Alternatively, the water-repellentcoating is applied after the plurality of particles is introduced ontothe top surface and cured as the particles are melted with heat.

The applied particles are contained within the textile fabric asdiscrete particles. In addition, particles that are larger than the gapwidths remain on the top surface of the textile fabric. In order toincorporate the particles into the textile fabric, the particles in theplurality of particles are melted using applied heat. Suitable methodsfor applying heat to a textile fabric are known and available in the artand include using radiation, hot air or a heated surface in lightcontact with the elevated areas of the top surface.

In one embodiment, the textile fabric is cooled following heating tomelt the plurality of particles. After heating and cooling, at least aportion of the plurality of surface yarns or filaments within thesurface yarns within elevated areas of yarns of the textile fabric arefree of melted particles. Applying heat to melt the plurality ofparticles improves at least one of overall durability, fluid penetrationresistance and cut-edge fraying resistance of the fabric. In oneembodiment, vacuum is applied to the bottom surface of the fabric whileapplying heat to the top surface to melt the plurality of particles.

Referring now to FIG. 4 , an embodiment of the textile fabric 200 isillustrated. As illustrated, the textile fabric includes a plurality ofyarns 202 looping in and out of the top surface 240 and the bottomsurface 242 of the textile fabric with a given repeating interval 235.In one embodiment, the yarns are bulked and gaps among the yarn-formingfilaments or fibers are present. The plurality of yarns in the textilefabric form a textured surface pattern of elevated areas of yarns 234,wherein the bulked yarns remain bulked and the gaps between filaments orfibers remain open, and depressed areas of yarns 236, wherein theinter-looped yarns are compressed and the gaps widths among filaments orfibers is reduced. When cut to size, the yarn ends at the cut edges 207are vulnerable to fray and “fuzz”.

Particles ranging from particles 218 that are smaller than the gapwidths among the fibers or filaments of the yarns, to particles 219 thatare larger are applied to the top surface of the fabric. Application ofthe particles is followed by the application of heat at a temperatureabove the melting point of the particles but below the melting point ofthe fibers or filaments in the yarns. Within the elevated areas of yarnsmost of the particles 218 proceed into the surface gaps and are locatedunder the exposed surface of the yarns, leaving the fibers or filamentsforming the yarns mostly exposed. Within the depressed areas of yarnsthe particles tend to accumulate towards the center of the depressedareas. Most of the large or small particles remaining over the elevatedareas can be propelled into the depressed areas using vacuum, vibrationor brushing applied either simultaneously or sequentially.

After heat is applied to melt the particles the melted particle resin atthe elevated areas of yarns, including the majority of melted particleresin located within the yarns and the small amount of melted particleresin located at or near the top surface improve surface abrasionresistance and edge fraying resistance The melted particle resin andsolid particles within the depressed areas of yarns may remain on thetop surface without affecting the fibrous feel of the fabric as meltedparticle resin and solid particles on the top surface are located belowand surrounded by the elevated areas of yarns. In summary, applying heattoward the top surface melts the particles to produce melted particleresin which flows 22 in the molten state and bond the fibers andfilaments within the yarns and adjacent yarns to each other. Thisbonding with melted particle resin stabilizes the textile fabric topsurface and the cut edges while leaving the top surface with a texturedand textile feel.

Referring now to FIG. 5 , in one embodiment, the textile fabric 200 iscombined with a barrier layer 201 and embossed with a coarser and deeper“macro pattern”, creating new raised areas of fabric 250 and loweredareas of fabric 252. The new elevated areas and depressed areas define athree-dimensional surface. In one embodiment, the textile fabric andbarrier layer are combined and subsequently embossed. A heated embossingtool (not shown) with projections deeper than the original thickness ofthe textile fabric and arranged with a spacing wider than the spacingbetween elevated areas of yarns and depressed areas of yarns presses thetextile fabric and barrier layer into a soft and resilient back-up plateor roll 299, for example, silicon rubber. The silicon rubber surfaceconforms, withstands high temperatures and releases any resin thatpenetrates through at the highly deformed lowered areas. As a result ofthe deep embossing the depth of the embossed fabric exceeds thethickness of the original fabric. The barrier layer is usuallymaintained in the raised areas, which have been subjected to negligibledeformation, and compromised in the lowered areas, which have beenhighly deformed by the projections of the embossing tool.

A plurality of particles ranging in size from smaller than the gapwidths on the top surface of the yarns to larger than the gap widths onthe top surface of the yarns are applied to the top surface of thetextile fabric. These different size particles can be applied separatelyor simultaneously. Suitable methods for applying the particles includesifting. In one embodiment, particles 218, which are smaller than thegaps among the filaments or fibers within the yarns penetrate the yarns.Particles 219 that are larger tend to descend down into the bottom ofthe lowered areas of the textile fabric by simple gravity. The largerparticles, as well as any smaller particles that may be located at theelevated areas may be aided to move into the compromised lowered areasby applying vacuum under the fabric, vibrating the fabric, blowing aironto the fabric, or any combination of these techniques, appliedseparately or simultaneously. When the accumulated particles in thelowered areas melt, the melted particle resin fills and seals openingscreated in the barrier by embossing. In one embodiment, the meltedparticle resin in the lowered areas protrudes locally over the fibers orfilaments of the yarns without affecting surface tactility in thetextile fabric as the melted particle resin remains below the yarnsurface in the raised areas.

In one embodiment, at least parts of the fibers or filaments in theraised areas are exposed and are free of melted particle resin afterheat is applied to melt the particles. As heat applied toward the topsurface melts the smaller particles, allowing the molten particles 220to flow into the yarns, the top surface of the textile fabric and thecut edges are stabilized while retaining the fibrous feel of the topsurface. The melting temperatures of the smaller particles and largerparticles may be the same or different, and heat may be applied to meltboth simultaneously or separately. In addition, heat may be applied tomelt the particles gradually.

In other embodiments, the textile fabric illustrated in FIG. 5 is anyfabric, woven, knit, stitchbonded or nonwoven, built with or withoutyarns, using filaments or staple fibers. In other embodiments, thetextile fabric includes pre-shaped micro patterns exhibiting elevatedand depressed areas. In one embodiment, the textile fabric is initiallyflat without any elevated or depressed areas of yarns. In oneembodiment, the textile fabric is pre-treated with repellent solutions.In one embodiment, the textile fabric is treated with solutionscontaining particles of a smaller size than the openings among surfacefibers or filaments. If the textile fabric is embossed with a barrierattached to the bottom surface, particles applied to the top surfacethat remain above the yarns, fibers or filaments at the elevated areasof yarns or raised areas of the textile fabric can be directed to thedepressed areas of yarns or lowered areas of the textile fabric wherethe barrier may be compromised by the embossing action to restore thebarrier and to stabilize the fabric.

Referring to FIGS. 6 and 7 , in one embodiment, a textile fabric 501 isincorporated into a composite 500. As shown in FIG. 6 , the textilefabric 501 is placed over or pre-attached to a barrier layer 505followed by placement over a cushioning layer 510. The cushioning layereliminates the need for the soft silicon rubber that is used to form theembossed fabric of FIG. 5 and is attached permanently to the barrier andthe fabric after being embossed with heat as shown in FIG. 7 . As shownin FIG. 6 , the textile fabric, in a similar manner to the fabric ofFIG. 4 , includes a plurality of yarns 502 looping in and out of the topsurface 540 and the bottom surface 542 of the textile fabric forming thetextured surface pattern of elevated areas of yarns 534 and depressedareas yarns 536 with a given repeating interval 535. When cut to size,the textile fabric in the composite includes cut edges 507.

As in the sequence described in relation to FIGS. 4 and 5 , a pluralityof low-melting particles is deposited onto the textile fabric in thecomposite of FIG. 6 , for example, by sifting. The particles can beadded in a single application or in multiple applications. In oneembodiment, at least some of the particles penetrate the gaps betweenthe yarns or filaments. Subsequently applied heat melts the particles520 that migrate into the yarns and into the depressed areas of theyarns of the fabric, away from the top surface, stabilizing the surfacewithout losing the textile feel of the surface.

Referring to FIG. 7 , with or without the pre-application of particlesto the face fabric, and with or without preheating the face fabric tomelt such particles, if any, the layers of FIG. 6 are embossed with amacro pattern and laminated with heat, integrating the three layers andproducing the composite 500 illustrated in FIG. 7 . The macro patterncreates raised areas 515 and lowered areas 516 repeating with a givenspacing 517. The particles and resin deposited onto the elevated areasand the melted particle resin that migrates into the textile fabric, ifany, stabilize the top surface and the cut edges of the composite. Thebarrier layer is subject to compromise at the bottom of the loweredareas where the projections of the embossing tool force the fibers andthe barrier layer open.

The barrier layer is usually maintained in the embossed raised areas butmay be compromised in the embossed lowered areas. A plurality oflow-melting particles is introduced onto the top surface 540 of thefabric layer in one or more applications, in a manner as depicted, forexample, in FIG. 5 . The particles in the plurality of particles can allbe the same size or can have a plurality of different sizes. As wasdiscussed above with regards to FIG. 5 , the particles in the loweredareas tend to descend into the lowered areas and accumulate near thecompromised barrier bottom by simple gravity as these particles do notenter the smaller gaps between the fibers or filament within the raisedareas. Vibration or blown air, preferably combined with vacuum appliedunderneath through the backing layer in cases wherein the backing layeris air-permeable, is used to promote the concentration of particles atthe lowered areas and to minimize or eliminate particles within theraised areas. After subsequent heat treatment, the compromised barrierat the bottom of the lowered areas is restored, and some degree of extrastability is added to the entire surface with limited frequency ofmelted particles on the surface.

The process used in FIGS. 6 and 7 can be applied to any surface fabricattached to a barrier layer. The surface fabric may be formed withindividual fibers or filaments instead of yarns, may be initially flatand non-textured and may or may not be pre-treated with fine particlesentering between surface filaments or fibers. After embossing with adeep pattern, particles coarser or finer than the gap widths among thesurface fibers or filaments that remain on the top surface at the raisedareas of the textile fabric are directed to the lowered areas withvacuum, blown air, vibration, sweeping by brushing or combinations ofthese techniques. This relieves the raised areas of fabric fromunnecessary surface resin while reinforcing the barrier within thedepressed areas.

Referring now to FIG. 8 , exemplary embodiments are directed to a methodfor improving surface and edge durability and resistance to fluidpenetration in a textile fabric 400. Initially, the desired textilefabric is selected 402. Suitable textile fabrics include, but are notlimited to knit fabrics, woven fabrics, tufted fabrics, nonwoven fabricsand stitchbonded fabrics. The textile fabric is formed from a pluralityof yarns or filaments or staple fibers and contains a plurality of gapsdisposed among the filaments or fibers. The yarns, filaments or fibershave a yarn melting point. In one embodiment, the yarns filament orfibers form a textured surface pattern with elevated areas of yarns anddepressed areas of yarns. The gaps define a plurality of gap widths

A determination is then made regarding whether the textile fabric is tobe combined with a barrier layer to form a composite 404. If the textilefabric is to be incorporated into a composite, for example, with barrierproperties, the additional barrier layer is added to the textile fabric406. If the textile fabric is not to be combined with a barrier layer, adetermination is made regarding whether the textile fabric is to becombined with a backing layer 408, for example, a cushioning layer. Ifthe textile fabric is to be combined with the backing layer, the backinglayer is added and attached to the textile fabric 410.

A determination is then made regarding the type and composition of theparticles to be added, the size or sizes of the particles to be added,the melting temperature of each type of particle, the melt viscosity ormelt index of each type of particle, and the distribution pattern of theparticles to be attained across the top surface of the textile fabric412. In one embodiment, the particles for the plurality of particles areselected having a particle size less than a first gap width or a secondgap width to disperse particles in at least one of the openings betweenfilaments and the spacings between yarns. Having identified theparticles to be applied, a determination is then made regarding thenumber of applications 414 and the type of applications 416. Suitabletypes of applications include sifting and applying in a liquidsuspension.

A determination is then made regarding whether the textile fabric orcomposite is to be embossed with a macro pattern 418. If the pattern isto be embossed, the textile fabric or composite is embossed with a macropattern containing raised areas and lowered areas 420.

Following embossing with the macro pattern or if the textile fabric isnot to be embossed, the selected plurality of particles is dispersed onthe textile fabric 422. The particles are dispersed in accordance withthe type of particles selected, the type of application, the number ofapplications and the desired distribution of particles. In oneembodiment, at least one of dry sweeping or brushing, vacuum, vibration,or blown air is applied to the textile fabric to direct particles thatfail to enter the gaps between the surface filaments or fibers at theraised areas into the lowered areas. In one embodiment, the plurality ofparticles includes particles having a size smaller than at least one gapwidth in the plurality of gap widths and a particle melting pointtemperature lower than the yarn melting point. In one embodiment,dispersing the plurality of particles comprises sifting the plurality ofparticles onto a top surface of the textile fabric. In one embodiment,dispersing the plurality of particles includes incorporating theplurality of particles into a liquid suspension, applying the liquidsuspension to a top surface of the textile fabric and evaporating aliquid from the liquid suspension after applying the liquid suspensionto the top surface, and optionally wiping the surface with a wet or drytool to cause the particles to proceed between the surface fibers orfilaments and away from the surface.

After the particles are dispersed on the textile fabric and directed tothe desired locations, a determination is made regarding how heat isgoing to be applied to melt the particles and to disperse the resultingmelted particle resin through the textile fabric and yarns 424.Sufficient heat is applied to the textile fabric to melt particles 426within the plurality of particles dispersed within the yarns. In oneembodiment, applying heat to the textile fabric includes using at leastone of radiant heating, convection and conduction on a top surface ofthe textile fabric.

Referring to FIG. 9 , exemplary embodiments are also directed to amethod for making a fabric having increased resistance to one or more ofsurface wear, edge fraying or fluid penetration. A plurality oflow-melting particles is introduced onto a top surface of a textilefabric 602. The top surface includes a plurality of surface fibers andgaps among the plurality the plurality of surface fibers. In oneembodiment, the elevated areas and depressed areas define athree-dimensional surface. In one embodiment, the surface fibers areyarns, and the elevated and depressed yarns are defined by the loopingof the yarns emerging from and returning into the fabric face. In oneembodiment the textile fabric is generally flat, and the surface textureis formed exclusively with yarn loops.

In one embodiment, the plurality of low-melting particles is introducedonto the top surface includes sifting the plurality of particles intothe top surface of the fabric, for example as a dry powder. In anotherembodiment, the plurality of low-melting particles is incorporated intoa liquid suspension, e.g., water with or with a surfactant. The liquidsuspension is applied to the top surface of the fabric. In oneembodiment, the liquid suspension is applied only to the elevated areasof the top surface. In one embodiment, the method includes anevaporative heating step to evaporate the liquid from the liquidsuspension following application of the liquid suspension to the topsurface and before applying heat sufficient to melt the plurality ofparticles.

In one embodiment, the plurality of low-melting particles descendsdisproportionately on the depressed areas rather than the elevated areaswhen introducing the plurality of low-melting particles onto the topsurface. In one embodiment, the particles or powder has a particle sizegreater than a size of the gaps among the plurality of surface fibers inthe elevated areas. In addition, a majority of the plurality ofparticles are located in the depressed areas. In one embodiment, theplurality of particles includes larger particles and smaller particles.The smaller particles pass into the gaps among the surface fibers, andthe larger particles collect in the depressed areas. In one embodiment,the plurality of particles or powder is sifted to separate largerparticles from the smaller particles.

A desired planar pattern of particle distribution and depth ofpenetration from the top surface of the plurality of low-melt particlesinto the gaps is established 604. In one embodiment, the textile fabricincludes upper strata, and establishing the desired depth of penetrationis established such that a majority of the plurality of particles orpowder are located within the upper strata. In one embodiment, a vacuumis applied to a bottom surface of the fabric opposite the top surface tocontrol the planar distribution of the plurality of particles and thedepth of penetration of the plurality of particles into the fabric. Inone embodiment, vacuum is applied to the bottom surface whileintroducing the plurality of low-melting particles onto the top surface.In one embodiment, the fabric is vibrated to control the planardistribution and depth of penetration of the plurality of particleseither with or without the simultaneous application of vacuum.

Heat is then applied to the top surface to melt the plurality ofparticles or powder 606. The method of applying the heat, the conditionsduring heating, e.g., vacuum and vibration, the type of particles, theembossed pattern on the fabric, can affect the location and flow of themolten resin during heating. In one embodiment, at least a portion ofthe plurality of surface fibers are free of melted particle resin. Theportion of the plurality of surface fibers free of melted particle resinis located in the elevated areas of the flat fabric or the raised areasof the embossed pattern of the fabric either alone or as part of acomposite.

In one embodiment, application of heat to melt the plurality ofparticles improves at least one of overall durability, fluid penetrationresistance and cut-edge fraying resistance of the fabric. Suitablemethods for applying heat include, but are not limited to, usingradiation, hot air or a heated surface in light contact with theelevated areas of the top surface. In one embodiment. vacuum is appliedto a bottom surface of the fabric opposite the top surface whileapplying heat to the top surface to melt the plurality of particles.

In one embodiment, the textile fabric is incorporated into a compositeand the particles and heating applied to the composite. In oneembodiment, a water-repellent coating is applied to the textile fabric.In one embodiment, the water-repellent coating is applied beforeintroducing the plurality of low-melting particles onto the top surface.In another embodiment, the water-repellent coating is applied afterintroducing the plurality of low-melting particles onto the top surface.In addition to a single application of particles onto the top surface ofthe textile fabric, two or more applications of particles or powders canbe used. For example, a first application can be made with a first sizeor coarseness of particles and a second application with a second sizeor coarseness of particles. In one embodiment, two applications are madeusing the same size or coarseness of particles. In one embodiment, afirst application of particles is made to the textile fabric, and asecond application of particles are made following embossing of thetextile fabric containing the first application of particles.

In one embodiment, a barrier layer is located within the lower strata ofthe fabric or attached to a bottom surface of the fabric opposite thetop surface. The fabric is embossed to create embossed raised areas andembossed lowered areas. The barrier layer is maintained in the embossedraised areas and compromised in the embossed lowered areas. Therefore,the textile fabric itself and the embossed pattern can each includeraised areas and lowered areas. A plurality of low-melting particles isintroduced onto the embossed lowered areas. This can be the first orsecond application of particles. If it is the second application ofparticles, the first application of particles is made to the textilefabric or composite containing the textile fabric prior to embossing.Heat is applied to the top surface to melt the plurality of particlesand restore the barrier layer in the embossed lowered areas.

In one embodiment, a barrier layer is located within the lower strata ofthe textile fabric or attached to the bottom surface of the textilefabric opposite the top surface, and additionally the textile fabriccontaining the barrier layer is incorporated into an upper surface of acomposite. The composite is embossed to create the embossed raised areasand embossed lowered areas. The barrier layer is maintained in theembossed raised areas and compromised in the embossed lowered areas. Aplurality of low-melting particles is introduced onto the embossedlowered areas. This can be the first or second application of particles.If it is the second application of particles, the first application ofparticles was made to the textile fabric or composite containing thetextile fabric prior to embossing. Heat is applied to the top surface tomelt the plurality of particles and to restore the barrier layer in theembossed lowered areas.

Embodiments involving the use of dissolved polymers applied to thesurface or to the entire fabric and subsequently driven down into thefabric layers under the surface before applying heat can take advantageof many of the secondary treatments available to the embodimentsinvolving powder application. These embodiments include the addition ofactive non-dissolving particles that are mixed with the dissolvedpolymer in powder form, barrier layers introduced under the textilefabric or within a composite topped by the textile fabric, fine andsmooth needling applied to adjust the fluid blocking properties aftersolvent flash-off and curing, and multiple applications of the samepolymeric solution or different polymeric solutions with or withoutintermediate surface treatment involving extra solvent, and with orwithout intermediate heat setting.

In one embodiment, a polymer solution with a relatively high viscosityis first applied to the textile fabric and forced into the lower strataof the fabric. The solvent is then evaporated, creating a relativelyporous internal sublayer. In one embodiment, the polymer solution isheat-treated at this stage. Alternatively, the polymer solution is leftin place. A second application of a less viscous polymeric solutionseals the first sublayer partially or totally, creating a submergedfluid or gas barrier that can be engineered for special effects such asfluid blockage with or without vapor permeability. The viscosities ofeach application may be adjusted by adjusting the ratio of polymer tosolvent and can be tailored to the particular type of textile fabric

In one embodiment, the chemical composition of the suspended adhesiveparticles or the chemical composition of the dissolved polymers iscompatible with the fibers or yarns in the fabric. Chemical compositioncompatibility facilitates the formation of chemical bonds in addition tomechanical bonds by simply surrounding the fibers, yarns or fiberbundles of yarns. In one embodiment, the particles or dissolved polymersare either partially or totally incompatible in chemical compositionwith the fibers or yarns, but still convenient to form bonded layersusing heavier weights at a more conveniently lower cost, as in the caseof ground recycled textiles.

In one embodiment, the suspended particles or polymeric solution isapplied to the fabric using two or more discrete applications. Multipleapplications are used to achieve a desired balance of bulk, durability,edge stability, and planar stiffness in the fabric. In one embodiment,the type particles, the chemical compatibility of the of the particles,the use of additional fluid or solvent, and the form of the particles,i.e., suspension versus solution, are varied from application toapplication. For example, a first application utilizes polymers that areincompatible with some or all of the fibers in the fabric. The firstapplication is followed by the application of additional fluid to drivethe polymer under the surface of the fabric. A second application isthen made with a polymer that is chemically compatible with the fibers.The second application is also followed by the application of additionalfluid to drive the polymer under the surface of the fabric. Theresulting fabric has a lower strata stabilized with mechanical bonds andan upper strata under the surface stabilized with both mechanical andchemical bonds.

EXAMPLES

In a first example, a textile fabric as illustrated in FIG. 4 wasselected and included a plurality of yarns forming a flat structurehaving a textured surface pattern with a given repeating interval. Thesurface pattern included a plurality of protruding elevated yarn areasand a plurality of depressed yarn areas. The yarns were bulked with gapsopen between the filaments in the yarns. The surface gaps varied up toapproximately 0.004 inches or 100 microns. The textile fabric had aweight of 12 oz./sq. yd. (420 grams/sq. m) and a thickness of 0.09inches (2.25 mm). The textile fabric was treated with a water repellenttreatment.

Low melt polyester particles with a nominal particle diameter of 82microns were sifted onto the top surface 109 of the textile fabric at aweight totaling approximately 1.0 oz. per sq. yd. The particles landedon the elevated yarn areas with some direct penetration between thesurface fibers. Radiant heat was applied on the top surface to melt theapplied particles throughout the fabric. Surface abrasion resistance andcut-edge fraying or fuzzing resistance improved dramatically. Theelevated yarn areas remained fibrous. The top surface remained soft andtextile like. Air and water vapor permeability were not noticeablyaffected. Liquid penetration resistance improved, and spills remained onthe top surface for periods varying between several minutes and severalhours

In a second example using the same textile fabric as in FIG. 4 , the 82micron particles were dispersed in water containing a surfactant. Thedispersion was applied gently over the top surface of the fabric,touching only the elevated areas. The particles penetrated betweenfilaments. The fabric was dried, and the particles were activated withheat. Particle pick-up was approximately 0.6 oz./sq. yd. The thicknessof the fabric did not change. The surface stability and cut edge frayingresistance were satisfactory and equivalent to the textile fabric as inthe first example in which dry particles were applied using sifting. Airand water vapor permeability and resistance to spills were notnoticeably different from the textile fabric without the dispersedparticles.

In a third example, coarse particles having a particle size varyingbetween approximately 400 and 700 microns were sifted over the topsurface of the textile fabric to add approximately 0.35 oz./sq. yd. ofweight. The particles were chosen to have a high melt index in order toflow freely when heated and molten without requiring significantpressure. Particles landed essentially equally onto the elevated areasand the depressed areas. The resin in the particles was activated bylightly touching the surface with a “non-stick” hot iron. Sufficientmelted particle resin was found to be present on the elevated areas toresist fraying or fuzzing at the cut edges. The melted particle resin inthe depressed areas of yarns also melted due to radiation from theheated iron; however, that melted particle resin remained in placewithout substantial penetration. The thickness of the fabric remained atthe original 0.090 inches. Resistance to air, water vapor or spilledliquids remained the same as textile fabric without particles.

In a fourth example, the textile fabric was subjected to vacuum appliedto a bottom surface opposite the top surface of the fabric. The vacuumwas applied as fine 82 micron particles were sifted onto the topsurface. The distribution of particles or powder shifted toward theelevated areas, allowing air to pass through more freely as compared tothe denser depressed areas. No significant effect on liquid penetrationresistance was observed until added particle or powder weight wasincreased to approximately 2.6 oz./sq. yd. (86 gm/sq. m). Followingactivation of the applied particles or powder with radiant heat, surfacestability and edge fraying resistance improved further, whileconsiderable textile feel on the surface remained. Liquid penetrationresistance increased, with the textile fabric passing the 24 hr BritishSpill Test. However, water collected on the surface could still beforced-in by rubbing or by applying a pressure of approximately 20 psito simulate the pressure of stepping onto collected puddles.

In a fifth example, the face or top surface of the textile fabric ofFIG. 4 was converted to a liquid blocking layer by adding a secondseparate application of fine particles applied as a fine sifted powder.The fabric in the embodiment of the fourth example described above wassubjected to a second sifting of fine 82 micron particles or powder withsimultaneous vacuum and planar vibration during the second powderdeposition. In addition, vacuum was applied to the bottom face of thefabric as the fabric was being subjected to heat. The 1.0 oz./sq. yd. ofparticles or powder applied during the second deposition by siftingbrought the fabric weight up to 15.6 oz./sq. yd. After activation of thesecond application of particles or powder with radiant heat, the cutedges were highly stabilized. Air and water penetration resistanceincreased dramatically. Soapy water failed to penetrate the surface whenpuddles are brushed, rubbed or pressed. The surface maintained a semifibrous fabric feel, with sporadic yarn/filament sections protrudingbeyond molten polymer.

In a sixth example, the textile fabric of FIG. 4 was placed over a solidlow-melt barrier layer supported by a silicon rubber sheet, as shown inFIG. 5 . Pressure and heat were applied with a three-dimensional toolfrom the top surface of the fabric. The result was the three-dimensionaltextile fabric illustrated in FIG. 5 . The resulting deep embossed macropattern included deeper and coarser raised areas and lowered areas thatrepeated with a given spacing. The low melt resin backing layer meltedat the compacted lowered areas and penetrated into the textile fabric,developing local barrier failure. Approximately 0.5 oz./sq. yd. ofcoarse 400-700 micron particles or powder with a very high melt indexwere then sifted onto the embossed surface and radiant heat was appliedto the surface to melt the deposited particles. The effect of meltedparticle resin on the surface yarns within the raised areas was similarto that within the elevated areas in the fabric above before embossing,with melted particle resin intermittent along the surface yarns at theraised areas. The barrier layer still developed leaks at the lowestparts of the lowered areas, which caused the fabric to loseeffectiveness as a barrier to liquids. However, the surface yarns at thecut edges were stabilized and resistant to fraying, while the surfacemaintained a fibrous feel, with surface filament segments within raisedareas free of resin.

In a seventh example spill resistance was restored to the pre-embossedthree-dimensional textile fabric of the sixth example using a secondapplication of coarse 400-700 micron high-melt-index polyethylene powderor particles in addition to the first application performed on thetextile fabric. The second application of particles was performed bysifting with vacuum simultaneously applied to the bottom surface to add2.0 oz./sq. yd., bringing the total weight to 14.5 oz./sq. yd. Theparticles or powder guided by the preferential movement of air into thecompromised lowered areas visibly landed primarily in the lowered areas.Radiant heat was applied from the top surface with simultaneous vacuumapplied to the bottom surface of the textile fabric. The sample passedthe British spill test. The cut edges remained resistant to fraying.Portions of the fibers in the yarns within the raised areas remainedfree of adhesive, maintaining a fibrous feel. The melted particle resindid protrude over fibers at the bottom of the lowered areas but remainedbelow the level of the fibers in the raised areas.

In an eighth example, the textile fabric was simultaneously embossed,stabilized and laminated onto the backing layer. The textile layer wasplaced over a low melting barrier layer and a cushioning layer. Coarse400-700 micron low-melt particles or powder were sifted onto the topsurface 412, adding a weight of approximately 0.7 oz./sq. yd. Thecomposite was embossed and laminated with heat, integrating the threelayers or elements and producing the composite, for example asillustrated in FIG. 7 . Due to the presence of resin deposited onto theraised areas, the top surface and the cut edges of the composite werestabilized and resisted fraying and fuzzing. The barrier created by thelow-melt layer was also maintained within the raised areas of theembossed pattern of the composite, as the yarns locally shielded thelow-melt layer. The textile fabric and the entire composite stillexhibited permeability to fluids due to leakage within the compromisedlowered areas of the embossed pattern.

In a ninth example, fluid penetration resistance was restored to theembossed composite of the eighth example. A mixture of high melt index50/50 coarse and fine powders or particles was sifted upon the compositeas vacuum was applied to the bottom surface. The majority of theparticles or powder landed in the lowered areas. A small percentage ofthe finer powder landed in the raised areas, caught by the intersticesbetween the yarn filaments. The resulting composite was heated withradiant heat with vacuum continuing to be applied to the bottom surfaceto melt all powders. Adding approximately 1.6 oz. of particles or powderwas sufficient to fill the perforations in the low-melt barrier layerwithin the lowered areas 504 and to restore the composite so that itpassed the British spill test. Raising the added weight to 3.5 oz.sealed the upper surface totally, with the raised areas still partiallyfibrous and resistant to fraying at the cut edges.

Exemplary embodiments are directed to methods for making improvedtextile fabrics by introducing into the textile fabrics low-meltingpolymeric solutions or liquid dispersions or suspensions of polymericparticles or powders. Suitable solvents for the polymeric solutionsinclude, but are not limited to, organic solvents such as volatileorganic compounds, for example, short-chain alcohols including methanol,ethanol, n-propanol, isopropanol and butanol, ketones, for example,acetone methyl-ethyl ketone, and other volatile solvents, for example,toluene, xylene hexane, THF (tetrahydrofurane), DMF (dimethylformamide)and DMSO (dimethylsulfoxide). The volatile organic compounds can beflashed-off from the textile fabrics using one or more of vacuum andheat. Suitable organic solvents also include long-chain organics, forexample, oils, alcohols, naptha, and petroleum distillates. Long-chainorganic solvents dissolve selected polymers but may be difficult toremove from the textile fabric, which could contribute to soiling. Inone embodiment, the solvent is THF. Suitable polymers that are solublein THF include common thermoplastic polymers, for example, polyesters,polystyrenes, polyurethanes, polycarbonates, Nylon-6 and polyvinylalcohols. The THF can be flashed off after application to the surface ofthe textile fabric.

Water, in combination with surfactants, e.g., soaps, ethoxylatedpropylene glycol or lecithin, in very low percentages by weight issuitable to hold particulate or powdered low-melt adhesives in a liquidsuspension.

In one embodiment, the textile fabrics have three-dimensional surfaces.In one embodiment, the textile fabrics are incorporated into compositescontaining the textile fabrics on their surfaces. The composites containone or more additional layers such as barrier layers and backing layers.In one embodiment, the barrier layer or backing layer is laminated tothe textile fabric using a relatively flat heated tool resulting in acomposite with a flat face or with the general pattern of the textureoriginally present in the textile fabric. Alternatively, lamination of atextile fabric to a backing layer or barrier layer is achieved using athree-dimensional heated tool. The three-dimensional heated tool forms adeeper and coarser face texture with a depth exceeding the originalthickness of the textile fabric.

In one embodiment, the textile fabric is a nonwoven layer formed withfilaments or staple fibers. In one embodiment, the textile fabric isattached to a cushion layer. In one embodiment the fabric is attached toa barrier layer.

In one embodiment, a suspension of polymeric particles is created byintroducing the polymeric materials into a liquid. Suitable polymericparticles include, but are not limited to, low melting polyester,polyethylene, and acrylics. Suitable liquids include, but are notlimited to, water and water aided by surfactants. In one embodiment,suitable suspended polymeric particles or polymeric powders include, butare not limited to, fine polymeric powders commercially used inprocesses, for example, the bonding of non-wovens and coarser powdersproduced by grinding low melt polymers including polymers contained inrecycled fabrics or floorcoverings. These powders contain particleshaving a range of particle sizes suitable for use with the textilefabrics. Alternatively, a polymeric solution is created by dissolving atleast one polymer into a solvent.

In one embodiment, one or more repellents are added before or after theapplication and curing of polymeric particles or polymeric solution.Suitable repellents include but are not limited to acrylic copolymerswith PFOA (perfluorooctanic acid), acrylic polymers with stearic acid orother hydrophobic functional groups, and other soil and stain resistantpolymers and finishes such as perfluorocarbons.

In one embodiment, high-melting or non-melting fine elements are mixedwith the suspension of polymeric particles or polymeric solution toobtain special effects. These fine elements and desired effects includecolored particles for aesthetic purposes, hard particles to increaseresistance to abrasion and particles reacting to moisture or heat toproduce special visual or functional effects, including but not limitedto breathability, moisture absorbency and moisture repellency at thesurface.

In one embodiment, the polymeric solutions or suspensions of polymericparticles are introduced into the top surface of the textile fabric orto the entire textile fabric. Suitable processes for applying thepolymeric solutions or suspensions of polymeric particles include, butare not limited to, spraying, immersion and squeezing, and wet transfercoating. Immersion and squeezing is commonly referred to as padding.Each process for applying polymeric solutions or suspensions ofpolymeric particles can followed with the application of additionalsuspension liquid or solvent or solvent to reduce or to eliminate theadded adhesive polymer from the surface before the application of heat.

In one embodiment, the textile fabric and top surface of the textilefabric are flat. Alternatively, the textile fabric is embossed with athree-dimensional pattern that creates elevated areas and depressedareas in the textile fabric. In one embodiment, the three-dimensionaltexture or pattern is achieved by embossing the textile fabric with aheated tool having a pattern of projections that create the elevatedareas and depressed areas. In one embodiment, the fabric is formed byyarns that loop into and out of the top surface. The looping yarnscreate the surface texture of elevated areas and depressed areas. In oneembodiment, the slightly textured surface containing the looping yarnsis deeply textured by embossing with the coarse three-dimensionalpattern. In one embodiment, the elevated areas and depressed areas ofthe embossed textile fabric define a depth between the top of theelevated areas and bottom of the depressed areas greater than theoriginal thickness of the textile fabric.

The polymeric solutions or suspensions of polymeric particles can beapplied to both the elevated areas and depressed areas or selectively tothe elevated areas. In one embodiment, the polymeric solutions orsuspensions of polymeric particles are applied to the elevated areas,for example, using a fine spray or by making wet contact with a wetroller or brush, so that the polymeric solutions or suspensions ofpolymeric particles do not proceed into the depressed areas.

In one embodiment, an additional volume of the liquid in which theparticles are dispersed or dissolved, i.e., the solvent, is applied tothe top surface of the textile fabric following introduction of thepolymeric solutions or suspensions onto the top surface. Suitablemethods for applying the addition volume of liquid or solvent include,but are not limited to, wiping the surface with the additional volume ofliquid or solvent, spraying the additional volume of liquid or solventonto the surface and brushing the surface with the additional volume ofliquid or solvent. The additional volume of liquid or solvent issufficient to move or migrate at least a portion of the suspendedparticles or dissolved polymer away from and below the top fibroussurface of the textile fabric. In one embodiment, the additional volumeof liquid or solvent is sufficient to move or migrate all suspendedparticles or dissolved polymer away from and below the top fibrous face.In on embodiment, additional volume of liquid or solvent is sufficientto move the suspended particles or dissolved polymer to a controlleddepth below the top surface. The result of moving the suspendedparticles or dissolved polymer away from the top surface is fibers onthe top surface protruding above the polymer. The protruding or exposedfibers prevent excessive hardening of the top surface of the textilefabric, preserving the textile look and feel of the textile fabric.

In one embodiment, one or more repellents are added to the additionalvolume of liquid or solvent. In one embodiment, high-melting ornon-melting fine elements are mixed with the additional volume of liquidor solvents to obtain special effects as discussed above.

In one embodiment, the deposited polymer solution or suspended particlesare activated with heat to melt and set the polymer in situ. In oneembodiment, any added repellents are cured as the polymers applied tothe textile fabric are activated and set. Heat is applied to at least aportion of the textile fabric. Preferably, heat is applied to the entiretextile fabric. Suitable heat sources include, but are not limited to,radiant heat, hot air, and a heated contact surface. In one embodiment,the heated contact surface is applied to the textile fabric using lowpressure. In one embodiment. vacuum is applied to a bottom surface ofthe fabric opposite the top surface while applying heat to the topsurface.

In one embodiment, activation of the deposited particles or polymer isachieved by raising the temperature of the entire textile fabric to alevel sufficient to melt the polymer or polymer particles. In oneembodiment, the polymer or polymer particles are activated when thetextile fabric is embossed with the three-dimensional pattern using aheated tool equipped with surface projections. In one embodiment thepolymer or polymer particles are activated when the textile fabric islaminated to additional layers, for example, a barrier layer or abacking layer. In one embodiment, a soft and resilient back-up tool, forexample a silicon rubber back-up tool, is used to emboss the textilefabric with a depth exceeding the original thickness of the textilefabric. Alternatively, the textile fabric is embossed against aconformable cushioning backing, eliminating the need for a soft back-uptool as the textile fabric forms into the backing.

In one embodiment, a water-repellent is incorporated into the textilefabric. In one embodiment, a water-repellent coating is applied to thetextile fabric and cured before the suspension of polymeric particles orpolymeric solution is introduced into the fabric. Alternatively, thewater-repellent coating is applied after the suspension of polymericparticles or polymeric solution is introduced and cured with heat

The advantages and improvements associated with the textile fabriccontaining the activated polymer applied as a suspension of polymericparticles or as a polymeric solution vary depending upon the structureof the top surface of the fabric, the nature of the surface fibers oryarns, the amount of deposited particles, the melt characteristics ofthe particles, and the structure of the deposited particles. Theseadvantages and improvements include, but are not limited to, simplestabilization of the elevated areas of yarns and raised areas of fabricversus wear and abrasion, achieving a breathable fluid barrier withminimum hardening of the textile fabric surface, and blocking of fluidpenetration through the textile fabric without excessive hardening andwithout eliminating the fibrous feel of the top surface.

Referring now to FIG. 10 , exemplary embodiments are directed to amethod for stabilizing a surface of a textile fabric. A desired textilefabric 700 is selected. The textile fabric includes a top surface 702and a bottom surface 704 opposite the top surface. In one embodiment, anonwoven textile fabric formed with filaments or staple fibers isselected. The nonwoven textile fabric has a flat top surface.Alternatively, a textile fabric containing a plurality of looping yarnsentering and exiting the top surface is selected. The looping yarns inthe plurality of looping yarns include an upper portion of the yarnsadjacent the top surface. In one embodiment, the textile fabric is agenerally planar fabric. The textile fabric can be embossed with acoarse pattern containing elevated areas and depressed areas, asillustrated, for example, in FIGS. 5 and 7 . The textile fabric can beincorporated into a composite containing one or more additional layersattached to the bottom surface of the textile fabric. Suitableadditional layers include, but are not limited to, barrier layers 708and backing layers 710 including cushioning backing layers. Thecomposite can also be embossed with a coarse pattern.

In one embodiment, a plurality of polymeric particles 712 are suspendedin a liquid 714 to create a liquid suspension of polymeric particles. Asan alternative to a liquid suspension of polymeric particles, at leastone polymer is dissolved in a solvent to create a polymeric solution. Inone embodiment, additives are incorporated into the liquid suspension ofpolymeric particles or polymeric solution. These additives have amelting point above the melting points of the polymer particles andpolymers used to make the suspension or solution. Therefore, the meltingpoint of the additives is greater than any heat applied to the textilefabric to activate or melt the polymer particles or polymers. Theadditives affect at least one of a color of the textile fabric, anabrasiveness of the textile fabric, an absorptiveness of the textilefabric and antimicrobial properties of the textile fabric. In oneembodiment, a repellent is introduced into the liquid suspension ofparticles or the polymeric solution.

The liquid suspension of polymeric particles or polymeric solution isapplied to the top surface of the textile fabric or to the entiretextile fabric. Suitable methods for applying the liquid suspension ofpolymeric particles or polymeric solution include, but are not limitedto, immersion, spraying, rolling and brushing. When the suspension orsolution is applied only to the surface, an initial volume of the liquidsuspension of polymeric particles or polymeric solution is applied tothe top surface. This initial volume is sufficient to penetrate 718 fromthe top surface into the textile fabric a penetration depth 722 that isless than a thickness 724 of the textile fabric. When the textile fabricincludes looping yarns having an upper portion adjacent the top surface,the penetration depth is limited to the upper portion of the loopingyarns. When the textile fabric has been embossed with a coarse,three-dimensional pattern, the liquid suspension of polymeric particlesor the polymeric solution is applied only to the elevated areas of thetextile fabric embossed with the coarse pattern.

An additional volume of the liquid or the solvent 716 is added orapplied to the top surface of the textile fabric that already containsthe liquid suspension of polymeric particles or the polymeric solution.This additional volume is sufficient to carry at least a portion of theplurality of polymeric particles of polymer in solution into the textilefabric to a point within the textile fabric 720 that is below and awayfrom the top surface. Preferably, the additional volume of liquid orsolvent is sufficient to carry all of the polymer particles or polymerin solution to the point in the textile fabric away from the topsurface. Suitable methods for applying the additional volume of liquidor solvent include, but are not limited to, wet brushing the liquid orsolvent onto the top surface, wet rolling the liquid or solvent onto thetop surface, spraying the liquid or solvent onto the top surface andcombinations thereof.

In one embodiment, additives are incorporated into the additional volumeof liquid or solvent. These additives have a melting point above themelting points of the polymer particles and polymers used to make thesuspension or solution. Therefore, the melting point of the additives isgreater than any heat applied to the textile fabric to activate or meltthe polymer particles or polymers. The additives affect at least one ofa color of the textile fabric, an abrasiveness of the textile fabric, anabsorptiveness of the textile fabric and antimicrobial properties of thetextile fabric. In one embodiment, a repellent is introduced into theadditional volume of liquid or solvent.

Heat, vacuum, forced air or combinations thereof are applied to at leastone of the top surface, the bottom surface or to the entire the textilefabric or the composite containing the textile fabric, for example, inan air circulating oven or finishing frame. Suitable mechanisms forapplying heat include, but are not limited to, conduction, convectionand thermal radiation. Conduction utilizes either flat heated plates ortextured heated plates. The textured heated plates embossed athree-dimensional pattern into the textile fabric or composite whiletransferring heat into the textile fabric. The heated plates are appliedeither with or without pressure applied to the textile fabric. Theapplied heat is sufficient to evaporate at least a portion the liquid orsolvent applied to the textile fabric. Preferably, the applied heat issufficient to evaporate all liquid and solvent applied to the textilefabric. The applied heat is also sufficient to melt, in situ, theplurality of polymer particles or the polymer contained in solution.

In one embodiment, the heat-set textile fabric containing the meltedpolymeric particles or melted polymer is needled with smooth fineneedles to allow free water vapor penetration through the textilefabric.

The foregoing written description uses examples of the subject matterdisclosed to enable any person skilled in the art to practice the same,including making and using any devices or systems and performing anyincorporated methods. The patentable scope of the subject matter isdefined by the claims, and may include other examples that occur tothose skilled in the art. Such other examples are intended to be withinthe scope of the claims.

What is claimed is:
 1. A method for improving abrasion resistance in a top surface of a textile fabric, the method comprising: suspending a plurality of low-melting polymeric adhesive particles having a particle melting point that is lower than a melting point of fibers forming the top surface in a liquid to create a liquid suspension of low-melting polymeric adhesive particles; applying the liquid suspension of low-melting polymeric adhesive particles to the textile fabric; applying a volume of additional liquid without any low-melting polymeric adhesive particles to the top surface of the textile fabric, the volume sufficient to carry at least a portion of the plurality of low-melting polymeric adhesive particles into the textile fabric and away from the top surface; and applying heat to the textile fabric after applying the volume of the additional liquid, the heat sufficient to evaporate the liquid applied to the textile fabric and to melt the plurality of low-melting polymer adhesive particles in situ without melting the fibers forming the top surface.
 2. The method of claim 1, wherein applying the liquid suspension comprises immersing the textile fabric in the liquid suspension.
 3. The method of claim 1, wherein applying the liquid suspension comprises applying the liquid suspension uniformly to a top surface of the textile fabric.
 4. The method of claim 1, wherein at least a portion of the low-melting polymeric adhesive particles comprise a chemical composition compatible with fibers in the textile fabric to form chemical bonds with the fibers.
 5. The method of claim 1, wherein at least portion of the low-melting polymeric adhesive particles comprise ground recycled textile products.
 6. The method of claim 1, wherein suspending the plurality of low-melting polymeric adhesive particles comprises suspending a plurality of polyester, polyethylene, polypropylene polyurethane, polyvinyl acetate, polyvinyl alcohol, polyamide or acrylic particles.
 7. The method of claim 1, wherein applying the liquid suspension further comprises applying an initial volume of the liquid suspension to the top surface of the textile fabric, the initial volume sufficient to penetrate from the top surface into the textile fabric with a penetration depth that is less than a thickness of the textile fabric.
 8. The method of claim 1, wherein applying the volume of the additional liquid comprises wet brushing the liquid onto the top surface, wet rolling the liquid onto the top surface, spraying the liquid onto the top surface, or combinations thereof.
 9. The method of claim 1, wherein the liquid comprises water containing surfactants and the additional liquid comprises only water.
 10. The method of claim 1, wherein the method further comprises incorporating additives comprising a melting point that is higher than a temperature of the step of applying heat to the textile fabric into at least one of the liquid suspension of particles and the volume of the additional liquid, the additives affecting at least one of a color of the textile fabric, an abrasiveness of the textile fabric, an absorptiveness of the textile fabric and antimicrobial properties of the textile fabric.
 11. The method of claim 1, wherein the method further comprises selecting a textile fabric comprising a plurality of looping yarns, the plurality of looping yarns comprising an upper portion adjacent the top surface.
 12. The method of claim 1, wherein: the method further comprises embossing the textile fabric with a coarse pattern comprising elevated areas and depressed areas before the application of the liquid suspension of the low-melting polymeric adhesive particles to the textile fabric; and applying the liquid suspension further comprises applying the liquid suspension of low-melting polymeric adhesive particles only to the elevated areas of the textile fabric embossed with the coarse pattern.
 13. The method of claim 1, wherein the method further comprises adding a repellent into at least one of the liquid suspension of particles and the volume of the additional liquid.
 14. The method of claim 1, wherein the method further comprises needling the textile fabric comprising melted polymeric particles with smooth fine needles to facilitate water vapor penetration through the textile fabric.
 15. A method for improving abrasion resistance of a top surface of a textile fabric, the method comprising: depositing a layer of low-melting polymeric adhesive particles having a particle melting point lower than a melting point of fibers forming the top surface of the fabric onto the top surface of the textile fabric; applying, subsequent to the deposition of the layer of low-melting polymeric adhesive particles onto the top surface of the textile fabric, a volume of liquid onto the top surface to cause at least a portion of the particles deposited onto the top surface to be driven below the top surface; and applying heat to the fabric to evaporate the applied volume of liquid and to melt the low-melting polymeric adhesive particles in situ.
 16. The method of claim 15, wherein depositing the layer of low-melting polymeric adhesive particles comprising sifting the low-melting polymeric adhesive particles or blowing the low-melting polymeric adhesive particles with air.
 17. The method of claim 16, wherein the method further comprises applying vacuum to a bottom surface of the textile fabric opposite the top surface while depositing the layer of low-melting polymeric adhesive particles.
 18. The method of claim 15, wherein applying the volume of liquid comprises wet brushing, wet rolling, or spraying. 